Method for the manufacture of a saddle made of composite material, in particular for a bicycle

Abstract

Saddle made of composite material, in particular for a bicycle, comprising a support structure provided with a padding having a seating surface. The support structure comprises a plurality of first layers of high-rigidity composite material having an opening formed centrally therein and a second layer of composite material with a rigidity less than that of the first layers, fixed to the latter along a superimposed surface covering the opening so as to form an elastically yielding zone which is preferably located in the prostatic and ischiatic zones of the seat of the saddle.

1. A method of manufacturing an integral saddle, comprising:
 hollow-punching a plurality of first layers of high-rigidity composite material including high-modulus fibers, so as to define a profile of a support structure and at least one opening in each of said first layers; 
 hollow-punching at least one second layer made of high-elasticity composite material including high-elasticity fibers and having a rigidity less than that of said first layers, so as to leave said at least one second layer substantially imperforate; 
 superimposing said first layers and said at least one second layer inside a first mold so as to ensure an alignment of the openings in said first layers, a portion of said at least one second layer being disposed coextensively with said openings so as to cover or block said openings; 
 molding and fixing said first layers and said at least one second layer inside said first mold by means of a thermosetting resin, so as to provide an elastically yielding zone in the region of said openings to form said support structure; 
 extracting said support structure from said first mold; 
 inserting said support structure into a second mold; and 
 expanding an elastomer material in said second mold to form a cover over a top of said support structure to obtain said integral saddle. 
 
   
   
     2. The method according to  claim 1 , wherein the superimposing includes arranging at least one of said first layers inside said first mold, superimposing said at least one second layer on top of said one of said first layers and superimposing remaining ones of said first layers on top of said at least one second layer. 
   
   
     3. The method according to  claim 1 , wherein the molding and fixing of said first layers and said at least one second layer inside said first mold includes pre-impregnating said first layers and said at least one second layer with said thermosetting resin. 
   
   
     4. The method according to  claim 1 , wherein the molding and fixing of said first layers and said at least one second layer inside said first mold includes injecting resin inside said first mold. 
   
   
     5. The method according to  claim 1 , wherein said first layers are hollow-punched to have different dimensions to create a thinning or tapered effect along edges of said support structure while maintaining unchanged said openings. 
   
   
     6. The method according to  claim 1 , wherein the superimposing is so effected that said at least one second layer is interposed between two of said first layers. 
   
   
     7. A method of manufacturing an integral saddle, comprising:
 hollow-punching at least one first layer of high-rigidity composite material including high-modulus fibers, so as to define a profile of a support structure and at least one opening in said at least one first layer; 
 hollow-punching at least one second layer made of high-elasticity composite material including high-elasticity fibers and having a rigidity less than that of said at least one first layer, so as to leave said at least one second layer substantially imperforate; 
 superimposing said at least one first layer and said at least one second layer inside a first mold so that a portion of said at least one second layer is disposed coextensively with said opening so as to cover or block said opening; 
 molding and fixing said at least one first layer and said at least one second layer inside said first mold by means of a thermosetting resin, so as to provide an elastically yielding zone in the region of the covered or blocked opening to form said support structure; 
 extracting said support structure from said first mold; 
 inserting said support structure into a second mold; and 
 expanding an elastomer material in said second mold to form a cover over a top of said support structure to obtain said integral saddle. 
 
   
   
     8. The method according to  claim 7 , wherein the molding and fixing of said at least one first layer and said at least one second layer inside said first mold includes pre-impregnating said at least one first layer and said at least one second layer with said thermosetting resin. 
   
   
     9. The method according to  claim 7 , wherein the molding and fixing of said at least one first layer and said at least one second layer inside said first mold includes injecting resin inside said first mold.